Alternative protein production and fermentation processes

What are alternative proteins?

Alternative proteins are derived from non-traditional sources such as plants, fungi, algae, or cultivated animal cells. They aim to replace or complement animal-based proteins while offering similar nutritional value and reducing environmental impact.

As global demand for sustainable food solutions grows, the production of these proteins through biotechnological processes, particularly precision fermentation, is gaining momentum. This technique enables controlled, efficient, and scalable protein production, positioning it as a transformative strategy for the future of the agri-food system.

The rise of alternative proteins

Demand for alternative proteins, such as plant-based, fungal, algae-derived, or even cultivated animal cell substitutes, has surged in recent years. Factors like global population growth, the environmental impact of livestock, and greater interest in health and wellness have driven the search for new sources of protein. While plant-based substitutes like soy and pea led the market initially, new methods using microorganisms and cell cultures as nutrient sources are now emerging.

This shift is largely due to the efficiency of new technologies and growing awareness that traditional livestock farming is unsustainable. The FAO (Food and Agriculture Organization of the United Nations) estimates that livestock farming is responsible for a significant share of greenhouse gas emissions, along with intensive water and land use. Alternative proteins, especially those derived from fermentation, offer a way to produce high-quality nutritional protein with a much smaller water and carbon footprint.

The role of precision fermentation

Fermentation involves using selected or engineered microorganisms to produce specific compounds or ingredients at industrial scale. These microbes may include bacteria, fungi, or genetically modified yeasts (or modified using other biotech tools) to produce proteins, fatty acids, enzymes, vitamins, and more. This approach enables:

  • Scalability: With the help of bioreactors and systems such as tangential flow filtration (TFF), it is possible to achieve large-scale production at competitive costs.
  • Consistency and quality: Fermentation processes are highly controllable, enabling consistent batches with stable protein content and purity.
  • Lower environmental impact: Compared to livestock, resource consumption and CO₂ emissions are significantly reduced.

Today, proteins like casein, albumin, collagen, and gelatin are being researched and produced through fermentation, for use in artificial dairy, meat analogues, and nutritional supplements.

Range of bioreactors and TFF systems for pilot plants

Associated processes and technologies

For fermentation to be effective, several key technologies are required. First, bioreactors must be able to precisely control variables like pH, temperature, and dissolved oxygen. These systems create optimal conditions for microbial growth, and when using single-use bioreactors, they also simplify operations by reducing cleaning costs and minimizing contamination risk.

Tangential flow filtration (TFF) plays a specific role in purifying and concentrating the products of fermentation. It allows scalable, reproducible separation of biomass and recovery of target proteins or metabolites.

In addition, advanced control systems, including AI-based platforms, are being incorporated to continuously monitor critical parameters and make real-time adjustments. This leads to:

  • Higher yield per volume: By maintaining optimal culture conditions, microbial strains work more efficiently.
  • Dynamic optimization: Machine learning algorithms process real-time data and adjust conditions on the fly.
  • Better resource use: More precise control reduces water and energy consumption while minimizing waste.

Advantages over traditional livestock

While many consumers are driven by ethical concerns, the food industry often focuses on profitability and supply chain stability. In times when grain prices or meat production may become unpredictable due to climate or geopolitical factors, producing proteins in a controlled environment, without vast land or specific weather conditions, is a major advantage.

  • Lower carbon footprint: Less methane and CO₂ emissions.
  • Lower water use: Producing 1 kg of microbial protein may require up to 90% less water than livestock.
  • Reduced space needs: Fermentation doesn’t need farmland, just facilities with the right technology.

That said, challenges around scalability and CAPEX investment remain. However, with proper planning and public policy support, this model holds significant potential.

Market challenges and opportunities

Despite its advantages, this sector still faces barriers:

  • Regulatory approval: New alternative products require solid food safety data to gain approval from bodies like the EFSA (Europe) or FDA (US).
  • Infrastructure investment: Scaling up production needs major investments in equipment and skilled personnel. In Europe, consortia and collaborative projects are pushing to expand biomanufacturing capacity.
  • Consumer acceptance: While meat reduction trends are growing, some consumers remain skeptical of “lab-made” proteins unless labeling is clear and real benefits are communicated. Transparent communication on nutritional and environmental value is key.
  • Production costs: Although prices have come down, the cost per kilo of fermentation-based protein still needs to drop further to compete directly with conventional meat.

Each of these challenges presents an opportunity. Companies developing technologies to lower fermentation costs or enhance protein functionality (e.g., improved amino acid profile or taste) will gain competitive advantage.

Conclusion

In short, producing alternative proteins through fermentation stands out as one of the most promising paths for the future of food and global sustainability. From reducing environmental impact to enabling the creation of new "functional" foods with enhanced nutritional profiles, the benefits are clear.

Despite the regulatory, scaling, and investment challenges, precision fermentation continues to gain momentum, with growing adoption by major food and pharmaceutical players. For TECNIC, this is an opportunity to lead and support the transition to a more sustainable food system, by providing equipment and systems that turn vision into reality.

Alternative protein production and fermentation processes

Frequently Asked Questions (FAQ)

1. What are alternative proteins?

They are non-traditional proteins from plants, fungi, algae, or cell cultures.

2. What is precision fermentation?

A biotech process using microbes to produce specific proteins or compounds.

3. Are fermentation-based proteins safe to eat?

Yes, they are regulated and must meet strict food safety standards.

4. What are the environmental benefits of alternative proteins?

They use less water, land, and emit fewer greenhouse gases than livestock.

5. Are alternative proteins healthy?

Yes, many alternative proteins are healthy. They often provide essential amino acids, are low in saturated fats, and contain fiber or beneficial nutrients.

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Cassette

We understand the importance of flexibility and efficiency in laboratory processes. That's why our equipment is designed to be compatible with Cassette filters, an advanced solution for a variety of filtration applications. Although we do not manufacture the filters directly, our systems are optimized to take full advantage of the benefits that Cassette filters offer.

Cassette filters are known for their high filtration capacity and efficiency in separation, making them ideal for ultrafiltration, microfiltration, and nanofiltration applications. By integrating these filters into our equipment, we facilitate faster and more effective processes, ensuring high-quality results.

Our equipment, being compatible with Cassette filters, offers greater versatility and adaptability. This means you can choose the filter that best suits your specific needs, ensuring that each experiment or production process is carried out with maximum efficiency and precision.

Moreover, our equipment stands out for its 100% automation capabilities. Utilizing advanced proportional valves, we ensure precise control over differential pressure, transmembrane pressure, and flow rate. This automation not only enhances the efficiency and accuracy of the filtration process but also significantly reduces manual intervention, making our systems highly reliable and user-friendly.

Hollow Fiber

We recognize the crucial role of flexibility and efficiency in laboratory processes. That's why our equipment is meticulously designed to be compatible with Hollow Fiber filters, providing an advanced solution for a broad spectrum of filtration applications. While we don't directly manufacture these filters, our systems are finely tuned to harness the full potential of Hollow Fiber filters.

Hollow Fiber filters are renowned for their exceptional performance in terms of filtration efficiency and capacity. They are particularly effective for applications requiring gentle handling of samples, such as in cell culture and sensitive biomolecular processes. By integrating these filters with our equipment, we enable more efficient, faster, and higher-quality filtration processes.

What sets our equipment apart is its 100% automation capability. Through the use of sophisticated proportional valves, our systems achieve meticulous control over differential pressure, transmembrane pressure, and flow rate. This level of automation not only boosts the efficiency and precision of the filtration process but also significantly diminishes the need for manual oversight, rendering our systems exceptionally reliable and user-friendly.

Contact General

Cellular configuration

The cellular configuration of the eLab Advanced is equipped with a pitched-blade impeller designed to support efficient mixing for cell culture processes in both laboratory development and early scale-up. The blade geometry promotes mainly axial flow, helping to distribute gases, nutrients and pH control agents uniformly throughout the vessel while keeping shear stress at a moderate level. This makes it suitable for mammalian, insect and other shear-sensitive cell lines when operated with appropriate agitation and aeration settings. In combination with the vessel aspect ratio and baffle design, the pitched blade supports stable foaming behavior and reproducible oxygen transfer, which is essential when comparing batches or transferring processes between working volumes.

Operators can fine-tune agitation speed to balance oxygen demand and mixing time without excessively increasing mechanical stress on the culture. 

Cellular configuration

The cellular configuration of the eLab Advanced is equipped with a pitched-blade impeller designed to support efficient mixing for cell culture processes in both laboratory development and early scale-up. The blade geometry promotes mainly axial flow, helping to distribute gases, nutrients and pH control agents uniformly throughout the vessel while keeping shear stress at a moderate level. This makes it suitable for mammalian, insect and other shear-sensitive cell lines when operated with appropriate agitation and aeration settings. In combination with the vessel aspect ratio and baffle design, the pitched blade supports stable foaming behavior and reproducible oxygen transfer, which is essential when comparing batches or transferring processes between working volumes.

Operators can fine-tune agitation speed to balance oxygen demand and mixing time without excessively increasing mechanical stress on the culture. 

Cellular configuration

The cellular configuration of the eLab Advanced is equipped with a pitched-blade impeller designed to support efficient mixing for cell culture processes in both laboratory development and early scale-up. The blade geometry promotes mainly axial flow, helping to distribute gases, nutrients and pH control agents uniformly throughout the vessel while keeping shear stress at a moderate level. This makes it suitable for mammalian, insect and other shear-sensitive cell lines when operated with appropriate agitation and aeration settings. In combination with the vessel aspect ratio and baffle design, the pitched blade supports stable foaming behavior and reproducible oxygen transfer, which is essential when comparing batches or transferring processes between working volumes.

Operators can fine-tune agitation speed to balance oxygen demand and mixing time without excessively increasing mechanical stress on the culture. 

Microbial configuration

The microbial configuration of the eLab Advanced is equipped with a Rushton turbine specifically designed for high-oxygen-demand processes such as bacterial and yeast fermentations. The radial-flow impeller generates strong mixing and intense gas dispersion, promoting high oxygen transfer rates and fast homogenization of nutrients, antifoam and pH control agents throughout the vessel. This makes it particularly suitable for robust microbial strains operating at elevated agitation speeds and aeration rates.

Operators can adjust agitation and gas flow to reach the required kLa while maintaining consistent mixing times, even at high cell densities. This configuration is an excellent option for users who need a powerful, reliable platform to develop and optimize microbial processes before transferring them to pilot or production scales.

Cellular configuration

The cellular configuration of the eLab Advanced is equipped with a pitched-blade impeller designed to support efficient mixing for cell culture processes in both laboratory development and early scale-up. The blade geometry promotes mainly axial flow, helping to distribute gases, nutrients and pH control agents uniformly throughout the vessel while keeping shear stress at a moderate level. This makes it suitable for mammalian, insect and other shear-sensitive cell lines when operated with appropriate agitation and aeration settings. In combination with the vessel aspect ratio and baffle design, the pitched blade supports stable foaming behavior and reproducible oxygen transfer, which is essential when comparing batches or transferring processes between working volumes.

Operators can fine-tune agitation speed to balance oxygen demand and mixing time without excessively increasing mechanical stress on the culture. 

Technical specifications

Materials and finishes

Typical
  • Product-contact parts: AISI 316L (1.4404), typical Ra < 0.4 µm (16 µin)
  • Non-contact parts/skid: AISI 304/304L
  • Seals/elastomers: platinum-cured silicone, EPDM and/or PTFE (material set depends on selection)
  • Elastomers compliance (depending on selected materials): FDA 21 CFR 177.2600 and USP Class VI
  • Surface treatments: degreasing, pickling and passivation (ASTM A380 and ASTM A968)
  • Roughness control on product-contact surfaces

Design conditions

Pressure & temperature

Defined considering non-hazardous process fluids (PED group 2) and jacket steam/superheated water (PED group 5), depending on configuration and project scope.

Reference design envelope
ModeElementWorking pressure (bar[g])Working pressure (psi[g])T max (°C / °F)
ProcessVessel0 / +2.50 / +36.3+90 / 194
ProcessJacket0 / +3.80 / +55.1+90 / 194
SterilisationVessel0 / +2.50 / +36.3+130 / 266
SterilisationJacket0 / +3.80 / +55.1+150 / 302
Jacket working pressure may also be specified as 0 / +4 bar(g) (0 / +58.0 psi[g]) depending on design selection; final values are confirmed per project.

Pressure control and safeguards

Typical
  • Designed to maintain a vessel pressure set-point typically in the range 0 to 2.5 bar(g)
  • Aseptic operation commonly around 0.2 to 0.5 bar(g) to keep the vessel slightly pressurised
  • Overpressure/underpressure safeguards included per configuration and regulations
  • Pressure safety device (e.g., rupture disc and/or safety valve) included according to configuration

Agitation

Reference ranges
Working volumeMU (Cell culture), referenceMB (Microbial), reference
10 L0 to 300 rpm0 to 1000 rpm
20 L0 to 250 rpm0 to 1000 rpm
30 L0 to 200 rpm0 to 1000 rpm
50 L0 to 180 rpm0 to 1000 rpm

Integrated peristaltic pumps (additions)

Typical

The equipment typically includes 4 integrated variable-speed peristaltic pumps for sterile additions (acid/base/antifoam/feeds). Actual flow depends on selected tubing and calibration.

ParameterTypical valueNotes
Quantity4 units (integrated)In control tower; assignment defined by configuration
Speed0-300 rpmVariable control from eSCADA
Minimum flow0-10 mL/minExample with 0.8 mm ID tubing; depends on tubing and calibration
Maximum flowUp to ~366 mL/minExample with 4.8 mm ID tubing; actual flow depends on calibration
Operating modesOFF / AUTO / MANUAL / PROFILEAUTO typically associated to pH/DO/foam loops or recipe
FunctionsPURGE, calibration, totaliser, PWMPWM available for low flow setpoints below minimum operating level

Gas flow control (microbial reference capacity)

Reference

For microbial culture (MB), gas flow controllers (MFC) are typically sized based on VVM targets. Typical reference VVM range: 0.5-1.5 (to be confirmed by process).

Working volume (L)VVM minVVM maxAir (L/min)O2 (10%) (L/min)CO2 (20%) (L/min)N2 (10%) (L/min)
100.51.55-150.5-1.51-30.5-1.5
200.51.510-301-32-61-3
300.51.515-451.5-4.53-91.5-4.5
500.51.525-752.5-7.55-152.5-7.5
O2/CO2/N2 values are shown as reference capacities for typical gas blending strategies (10% O2, 20% CO2, 10% N2). Final gas list and ranges depend on process and configuration.

Instrumentation and sensors

Typical

Instrumentation is configurable. The following list describes typical sensors integrated in standard configurations, plus common optional PAT sensors.

Variable / functionTypical technology / interfaceStatus (STD/OPT)
Temperature (process/jacket)Pt100 class A RTDSTD
Pressure (vessel/lines)Pressure transmitter (4-20 mA / digital)STD
Level (working volume)Adjustable probeSTD
pHDigital pH sensor (ARC or equivalent)STD
DO (pO2)Digital optical DO sensor (ARC or equivalent)STD
FoamConductive/capacitive foam sensorSTD
Weight / mass balanceLoad cell (integrated in skid)STD
pCO2Digital pCO2 sensor (ARC or equivalent)OPT
Biomass (permittivity)In-line or in-vessel sensorOPT
VCD / TCDIn-situ cell density sensorsOPT (MU)
Off-gas (O2/CO2)Gas analyser for OUR/CEROPT
ORP / RedoxDigital ORPOPT
Glucose / LactatePAT sensorOPT

Automation, software and connectivity

Typical

The platform incorporates TECNIC eSCADA (typically eSCADA Advanced for ePILOT) to operate actuators and control loops, execute recipes and manage process data.

Main software functions
  • Main overview screen with process parameters and trends
  • Alarm management (real-time alarms and historical log) with acknowledgement and comment option
  • Manual/automatic modes for actuators and control loops
  • Recipe management with phases and transitions; parameter profiles (multi-step) for pumps and setpoints
  • Data logging with configurable period and export to CSV; PDF report generation
Common control loops
  • Temperature control (jacket heating/cooling)
  • Pressure control (headspace) with associated valve management
  • pH control via acid/base addition pumps and optional CO2 strategy
  • DO control with cascade strategies (agitation, air, O2, N2) depending on package and configuration
  • Foam control (foam sensor and automatic antifoam addition)
Data integrity and 21 CFR Part 11

Support for 21 CFR Part 11 / EU GMP Annex 11 is configuration- and project-dependent and requires customer procedures and validation (CSV).

Utilities

Reference

Utilities depend on final configuration (e.g., AutoSIP vs External SIP) and destination market (EU vs North America). The following values are typical reference points.

UtilityTypical service / configurationPressureFlow / powerNotes
ElectricalEU base: 400 VAC / 50 Hz (3~)N/AAutoSIP: 12 kW; External SIP: 5 kWNA option: 480 VAC / 60 Hz; cabinet/wiring per NEC/NFPA 70; UL/CSA as required
Process gasesAir / O2 / CO2 / N2Up to 2.5 bar(g) (36.3 psi)According to setpointTypical OD10 pneumatic connections; final list depends on package
Instrument airPneumatic valvesUp to 6 bar(g) (87.0 psi)N/ADry/filtered air recommended
Cooling waterJacket cooling water2 bar(g) (29.0 psi)25 L/min (6.6 gpm)6-10 °C (43-50 °F) typical
Cooling waterCondenser cooling water2 bar(g) (29.0 psi)1 L/min (0.26 gpm)6-10 °C (43-50 °F) typical
Steam (External SIP)Industrial steam2-3 bar(g) (29.0-43.5 psi)30 kg/h (66 lb/h)For SIP sequences
Steam (External SIP)Clean steam1.5 bar(g) (21.8 psi)8 kg/h (18 lb/h)Depending on plant strategy

Compliance and deliverables

Typical

Depending on destination and project scope, the regulatory basis may include European Directives (CE) and/or North American codes. The exact list is confirmed per project and stated in the Declaration(s) of Conformity when applicable.

ScopeEU (typical references)North America (typical references)
Pressure equipmentPED 2014/68/EUASME BPVC Section VIII (where applicable)
Hygienic designHygienic design good practicesASME BPE (reference for bioprocessing)
Machine safetyMachinery: 2006/42/EC (until 13/01/2027) / (EU) 2023/1230OSHA expectations; NFPA 79 (industrial machinery) - project dependent
Electrical / EMCLVD 2014/35/EU; EMC 2014/30/EUNEC/NFPA 70; UL/CSA components and marking as required
Materials contactEC 1935/2004 + EC 2023/2006 (GMP for materials) where applicableFDA 21 CFR (e.g., 177.2600 for elastomers) - materials compliance
Software / CSVEU GMP Annex 11 (if applicable)21 CFR Part 11 (if applicable)
Standard documentation package
  • User manual and basic operating instructions
  • P&ID / layout drawings as per project scope
  • Material certificates and finish/treatment certificates (scope dependent)
  • FAT report (if included in contract)
Optional qualification and commissioning services
  • SAT (Site Acceptance Test)
  • IQ / OQ documentation and/or execution (scope agreed with customer)
  • CSV support package for regulated environments (ALCOA+ considerations, backups, time synchronisation, etc.)

Ordering and configuration

Project-based

ePILOT BR is configured per project. To define the right MU/MB package, volumes and options (utilities, sensors, software and compliance), please contact TECNIC with your URS or request the configuration questionnaire.

The information provided above is for general reference only and may be modified, updated or discontinued at any time without prior notice. Values and specifications are indicative and may vary depending on project scope, configuration and applicable requirements. This content does not constitute a binding offer, warranty, or contractual commitment. Any final specifications, deliverables and acceptance criteria will be confirmed in the corresponding quotation, technical documentation and/or contract documents.

Cellular configuration

The cellular configuration of the eLab Advanced is equipped with a pitched-blade impeller designed to support efficient mixing for cell culture processes in both laboratory development and early scale-up. The blade geometry promotes mainly axial flow, helping to distribute gases, nutrients and pH control agents uniformly throughout the vessel while keeping shear stress at a moderate level. This makes it suitable for mammalian, insect and other shear-sensitive cell lines when operated with appropriate agitation and aeration settings. In combination with the vessel aspect ratio and baffle design, the pitched blade supports stable foaming behavior and reproducible oxygen transfer, which is essential when comparing batches or transferring processes between working volumes.

Operators can fine-tune agitation speed to balance oxygen demand and mixing time without excessively increasing mechanical stress on the culture. 

Technical specifications

    ePILOT BR configuration questionnaire









    Project details



















    FAT:

    Shipment:

    Installation:

    SAT:

    IQ/OQ:


    Process and automation requirements























    MU only (cell culture)


    MB only (microbial)


    Utilities and infrastructure



    North America specific















    Connections, consumables and compliance












    EU specific




    North America specific


    Software / CSV (GMP)


    Validation, testing and documentation










    GMP / CSV


    Logistics and installation











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